Tool and Method for Forming Shower Base Elements

ABSTRACT

A tool and a method for creating a base element for a shower installation are disclosed. Specifically, the tool relates to a multi-level, rotary mounted form arm and an edge support for forming mortar into a properly sloped shower base. An improved alternative length adjustable form arm is disclosed that may be used independently to scrape or form a wall or ceiling, or, as a multi-use expandable straight edge.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent makes reference to U.S. Prov. App. No. 63/344,954 filed May 23, 2022 and incorporates that application, in its entirety, by reference.

FIELD OF THE INVENTION

The present invention relates to a tool and a method for creating a base element for a shower installation. Specifically, the present invention relates to a multi-level, rotary mounted form arm and an edge support for forming mortar into a properly sloped shower base. The expandable form arm may be detached and used to level, flatten, and form other flat surfaces.

BACKGROUND OF THE INVENTION

Currently, there are numerous methods of creating a drain pan for a shower installation. There are monolithic, precast products that make it possible to install a pre-made, properly sloped drain pan in a shower stall. Such products are installed, taped, and finished leaving a properly sloped drain pan ready for final tiling. Unfortunately, such products are costly.

Fixed dimension, non-tiled shower pans are constructed out of nylon reinforced fiber or plastic. These are installed directly on the slab. These products are reasonably priced. But their construction is not useful for tiled shower pans.

The most common method is for a concrete worker to form a properly sloped pre-shower slope element from mortar in the area where the shower stall is to be placed. Next, the concrete worker places a plastic shower liner down over the dried pre-drain element in the base of the shower stall. This shower liner conducts water that makes its way through the subsequently poured drain element and tiled floor to the drain. Next, the concrete worker forms the final properly sloped drain pan of the shower stall out of mortar. Finally, tile installers install tile over the drain pan of the shower stall.

This method is, however, very labor intensive and dependent on the skill of the artisan forming the mortar elements. What is needed then is a tool and a method of using the tool that facilitates and simplifies forming these elements of the base.

Therefore, what is needed is a tool and a method of using the tool that facilitates forming a properly angled pre-shower slope capable of supporting a plastic drain liner.

Also, what is needed is a tool and a method of using the tool that facilitates forming a properly angled shower pan on top of the plastic drain liner.

Finally, what is needed is a height-adjustable support element capable of being aligned such that drain pans of various lengths and widths may be formed.

SUMMARY OF THE INVENTION

The exemplary embodiment of the present invention comprises two components: 1) A rotary mounted form tool; and, 2) A height-adjustable support structure capable of being aligned to support the rotating end of the rotary forming tool. Also, the rotary mounted forming tool may be used independently as a multi-use expandable straight edge.

The rotary mounted forming tool is comprised of a central mount, or, a shaft/pivot that inserts vertically into a shower drain pipe.

Horizontally attached to the vertical shaft of the drain mount is a length-adjustable form arm. An adjustment screw end support may be vertically screwed through the terminal end of the form arm and is capable of supporting the terminal end of the form arm. An adjustment screw is used to fix the height of the end affixed to the vertical shaft.

The height-adjustable support structure is a plastic strip capable of being placed on the ground around the shower area. Cut into the strip at regular distances along its length are a series of vertical slots of different lengths. Placed crosswise into these slots at regular distances from one another are stabilizing elements. These stabilizing elements adjust the height of the height-adjustable support structure at various points on its outer periphery when it is installed.

The exemplary embodiment of the present invention is used in the following manner: First, the central mount of the rotary mounted forming tool is attached to the roughed in drain flange. Next, the length-adjustable form arm is inserted on the vertical shaft. Next, the fixing adjustment screw and the adjustment screw end support are adjusted so that the grade formed by the pre-shower slope is within code for a pre-shower slope. Next, the user mixes mortar and pours it into the shower pan area. Next, the user rotationally positions the form arm to mold a pre-shower slope. Next the user removes the rotary mounted form tool and length-adjustable form arm. Next, the user lets the pre-shower slope dry. Next, the user positions a shower liner over the cured pre-shower slope. Next, the user secures a shower liner lock plate over the drain flange. Next, the user positions a drain riser in the drain flange at the proper height. Next, the user removes the adjustment screw from the end of the form arm. Next, the user affixes the rotary mount form tool in the drain riser at the proper height and secures the fixing adjustment screw. Next, the user places the height-adjustable support structure around the peripheral extent of the shower pan area. Next, the user inserts stabilizing elements through vertical slots at suitable points along the length of the height-adjustable support structure to adjust the height of the height-adjustable support structure to reflect the proper code specified for the final grade of the shower pan. Next, the user mixes mortar and pours it into the shower pan area. Next, the user rotationally flexes the form arm to mold a shower pan. Next the user removes the rotary mounted form tool and length-adjustable form arm. Next, the user lets the shower pan dry. Finally, the tile installer installs tile over the cured shower pan.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a diagram showing the rotary mounted form tool and length-adjustable form arm.

FIG. 1 b is close-up diagram showing the rotary mounted form tool.

FIG. 2 is an elevation view showing the rotary mounted form tool and length-adjustable form arm being used to mold a pre-shower slope.

FIG. 3 is an elevation view showing the rotary mounted form tool and length-adjustable form arm being used to mold a shower pan area.

FIG. 4 is a plan view showing the rotary mounted form tool and length-adjustable form arm in typical relation to the height-adjustable support structure with stabilizing elements.

FIG. 5 is an elevation view showing the height-adjustable support structure slotted to support stabilizing elements.

FIG. 6 is a diagram showing an alternative embodiment of the rotary mounted form tool.

FIG. 7 is a schematic diagram of a cross section of an alternative embodiment of the rotary mounted form tool at location “A” as shown on FIG. 6 .

FIG. 8 is a schematic diagram of a cross section of an alternative embodiment of the rotary mounted form tool at location “B” as shown on FIG. 6 .

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIGS. 1 a, 1 b , and 2 through 5 the exemplary embodiment of the present invention comprises two components: 1) A rotary mounted forming tool 100; and, 2) A height-adjustable support structure 140 capable of being aligned to support the rotating end of rotary mounted forming tool 100.

Rotary mounted forming tool 100 is comprised of central mount 101 capable of being affixed to drain flange 110 and drain riser 131 of a shower stall. Central mount 101 has vertical shaft 103 affixed to it via ball joint 102. Central mount 101 may be affixed directly to drain flange 110 and subsequently affixed to drain riser 131. Central mount 101 has two sets of holes: 1) A first set 101 a driven such that central mount 101 may be affixed by bolts to drain flange 110; and, 2) A second set 101 b driven such that central mount 101 may be affixed by screws to drain riser 131.

Horizontally attached to vertical shaft 103 of central mount 101 is length-adjustable form arm 100 a. Vertical shaft 103 is equipped with visual markings showing the height of length-adjustable form arm 100 a above central mount 101. Vertical shaft 103 is affixed to central mount 101 by means of ball joint 102. Length-adjustable form arm 100 a is comprised of near arm 105 and distal arm 106. Length-adjustable form arm 100 a is attached to vertical shaft 103 at central pivot hole 104. Length-adjustable form arm 100 a is secured to vertical shaft 103 by means of adjustment screw 105 a. It will be obvious to one having skill in the art that adjustment screw 105 a is not the only means of affixing length-adjustable form arm 100 a to vertical shaft 103. Pins or clips may also be used in lieu of adjustment screw 105 a. Near arm 105 and distal arm 106 are adjustably affixed together by screws 107 a. Screws 107 a are inserted through holes and adjustable length slot 107 b. It will be obvious to one having skill in the art that the holes may be drilled in either near arm 105 or distal arm 106. Similarly, adjustable length slot 107 b is formed in the opposing distal arm 106 or near arm 105. Adjustment screw end support 108 may be vertically screwed through the terminal end of distal arm 106 and is capable of supporting the terminal end of distal arm 106 and attached near arm 105 by means of its affixed terminal pad 109.

Referring specifically to FIG. 2 , an alternative embodiment of the present invention is disclosed. In this embodiment, laser 111 generating laser point 111 a may be affixed to the distal end of distal arm 106. Laser point 111 a is projected onto the side of the shower enclosure.

Referring now to FIGS. 4 and 5 , height-adjustable support structure 140 is a plastic strip capable of being placed on the ground around the outer perimeter of the shower area. Cut or molded into height-adjustable support structure 140 at regular distances along its length are repeating series of vertical slots 142. Each slot in each series of repeating series of vertical slots 142 are different lengths. For example, the preferred embodiment of the present invention has slots that are ⅛″, ¼″, ½″, and ¾″ long and each slot is placed ½″ apart. Placed crosswise into these slots at regular distances from one another are stabilizing elements 141. Stabilizing elements 141 are used to adjust the height of height-adjustable support structure 140 at various points on its outer circumference when it is installed.

Referring again to FIGS. 1 a, 1 b and 2 through 5, the exemplary embodiment of the present invention is used in the following manner: First, central mount 101 of rotary mounted forming tool 100 is attached to roughed in drain flange 110. Next, central pivot hole 104 of length-adjustable form arm 100 a is inserted on vertical shaft 103. Next, fixing adjustment screw 105 a and adjustment screw end support 108 are adjusted so that the grade formed by length-adjustable form arm 100 a is within code for a pre-shower slope. The user tightens fixing adjustment screw 105 a. Next, the user mixes mortar and pours it into the shower pan area. Next, the user rotates length-adjustable form arm 100 a around vertical shaft 103 to mold a pre-shower slope. Next the user removes rotary mounted forming tool 100 and length-adjustable form arm 100 a from roughed in drain flange 110. Next, the user lets the pre-shower slope dry. Next, the user positions shower liner 121 over cured pre-shower slope 120. Next, the user secures shower liner 121 using shower liner lock plate 130 over drain flange 110. Next, the user positions drain riser 131 in shower liner lock plate 130 at the proper height. Next, the user removes adjustment screw end support 108 from the distal end of length-adjustable form arm 100 a. Next, the user screws rotary mounted forming tool 100 to drain riser 131. Next, the user places height-adjustable support structure 140 around the peripheral extent of the shower pan area. Next, the user inserts stabilizing elements 141 through vertical slots 142 at suitable points along the length of height-adjustable support structure 140 to adjust the height of height-adjustable support structure 140 such that the grade formed by length-adjustable form arm 100 a as it rests with its distal end on top of height-adjustable support structure 140 is set in compliance with the proper code specified for the final grade of the shower pan. Next, the user mixes mortar for shower pan 150 and pours it into the shower pan area. Next, the user rotationally flexes length-adjustable form arm 100 a on top of and around height-adjustable support structure 140 to mold a shower pan. Next, the user removes rotary mounted forming tool 100 and length-adjustable form arm 100 a from drain riser 131. Next, the user lets the shower pan dry. Finally, the tile installer installs tile over the cured shower pan 150.

Referring now specifically to FIG. 2 , an alternative embodiment of the present invention is used in an alternative manner: Specifically, laser point 111 a generated by laser 111 is aligned with level lines drawn on the sides and end of the shower stall. This is done both to form both pre-shower slope 120 and to form the shower pan. Height-adjustable support structure 140 is not required using this embodiment.

Referring now specifically to FIGS. 6, 7, and 8 , an alternative embodiment of the present invention is constructed in a different manner and used in a different way. Alternative length adjustable form arm 200 may be used as a multi-use expandable straight edge. Also, alternative length adjustable form arm 200 has a removable pin 206 that affixes it to a rotating element 207 circling around the vertical shaft 208 of a central mount. The vertical shaft 208 and central mount are inserted into a generally vertically disposed drain pipe and set up and used in the manner described supra.

Alternative length adjustable form arm 200 is constructed of stamped or molded segments 201, 202, 203, 204, and 205. Stamped or molded segments 201, 202, 203, 204, and 205 may be constructed of numerous materials that may be formed, molded, or machined in the proper shape. Such materials include aluminum, steel, fiberglass, Delrin, fiber reinforced plastic, and other similar substances. As illustrated in FIG. 7 (a cross section of alternative length adjustable form arm 200 taken at line “A” in FIG. 6 ), stamped or molded segment 201 may be hollow or solid and forms the core of alternative length adjustable form arm 200. Stamped or molded segment 202 is in turn slid, from the end, over stamped or molded segment 201. Stamped or molded segment 202 is retained on stamped or molded segment 201 by a linear cavity 201 b formed in stamped or molded segment 201. A solid or spring-loaded retainer clip 202 c affixed to stamped or molded segment 202 is insinuated in linear cavity 201 b machined or stamped into stamped or molded segment 201. As illustrated in FIG. 8 (a cross section of alternative length adjustable form arm 200 taken at line “B” in FIG. 6 ), stamped or molded segment 204 is slid, from the end, over stamped or molded segment 203. Stamped or molded segment 204 is retained on stamped or molded segment 203 by a linear cavity 203 b formed in stamped or molded segment 203. A solid or spring-loaded retainer clip 204 c affixed to stamped or molded segment 204 is insinuated in linear cavity 203 b machined or stamped into stamped or molded segment 203. This process may be repeated as many times as necessary to achieve any length of alternative length adjustable form arm 200.

It will be obvious to those having skill in the art that situationally the structure of the alternative length adjustable form arm 200 may be reversed by size: i.e. increasing larger (wider) stamped or molded segments 201, 202, 203, 204, and 205 may be linearly arranged just as increasingly smaller (narrower) stamped or molded segments 201, 202, 203, 204, and 205 may be linearly arranged. Also, it will be obvious to those having skill in the art that situationally the structure of the alternative length adjustable form arm 200 may be reversed in terms of how the segments are clipped together: i.e., linear cavities (for example 201 b and 203 b), may be solid or spring-loaded retainer clips (for example 202 c, 203 c, and 204 c).

Stamped or molded segments 202, 203, 204, and 205 each are finished with a linear edge 202 a, 203 a, 204 a, and 205 a. Each of these linear edges are co-linear with one another when stamped or molded segments 202, 203, 204, and 205 are assembled and fully extended with respect to one another. Alternative length adjustable form arm 200 may be comprised of as many stamped or molded segments as necessary to achieve any length of alternative length adjustable form arm 200.

Stamped or molded segments 201, 202, 203, 204, and 205 may be slid together and stored superimposed on one another. That is, stamped or molded segment 202 may be slid completely over stamped or molded segment 201; stamped or molded segment 203 may be slid completely over stamped or molded segment 202; stamped or molded segment 204 may be slid completely over stamped or molded segment 203; and, stamped or molded segment 205 may be slid completely over stamped or molded segment 204. Alternative length adjustable form arm 200 may be unclipped from rotating element circling around the vertical shaft by unpinning removable pin 206. Alternative length adjustable form arm 200 may be stored separately in a toolbox or hung on a belt. It will be obvious to those having skill in the art that situationally the structure of the alternative length adjustable form arm 200 may be reversed by size: i.e., increasingly larger (wider) stamped or molded segments 201, 202, 203, 204, and 205 may be linearly arranged just as increasingly smaller (narrower) stamped or molded segments 201, 202, 203, 204, and 205 may be linearly arranged.

Similarly, alternative length adjustable form arm 200 may be reextended but not reattached to rotating element circling around the vertical shaft. In this mode, when reextended, alternative length adjustable form arm 200 may be used as a multi-use expandable straight edge to, for example, scrape or form a wall or a ceiling covered in mud or in plaster. The linear edges that are co-linear with respect to one another when stamped or molded segments 202, 203, 204, and 205 are assembled and fully extended with respect to one another ensure this.

While the present invention has been described in what are thought to be the most useful and practical embodiments, it will be readily apparent to those having skill in the art that other variations may be readily conceived and created. Accordingly, these and all such other readily conceived and created variations are implicitly included in the spirit and scope of the present disclosure. 

What is claimed is:
 1. A system for forming and constructing a shower pan comprising: a) a rotary mounted forming tool comprising a generally perpendicular vertical shaft with a radially affixed length-adjustable form arm: i. wherein said radially affixed length-adjustable form arm is constructed of at least two interlocking segments wherein at least one of said interlocking segments may be slidable stored inside its neighboring segment; ii. wherein said radially affixed length-adjustable form arm is affixed at one end to said vertical shaft; and b) a height-adjustable support structure with affixed stabilizing elements wherein said stabilizing elements are transversely inserted through slots formed in said height-adjustable support structure.
 2. A system for forming and constructing a shower pan of claim 1 wherein the generally perpendicular vertical shaft is anchored at the drain of the shower.
 3. A system for forming and constructing a shower pan of claim 1 wherein the radially affixed length-adjustable form arm is constructed of aluminum.
 4. A system for forming and constructing a shower pan of claim 1 wherein the radially affixed length-adjustable form arm is constructed of fiberglass.
 5. A system for forming and constructing a shower pan of claim 1 wherein the radially affixed length-adjustable form arm is constructed of plastic.
 6. A system for forming and constructing a shower pan of claim 1 wherein the radially affixed length-adjustable form arm is constructed of Delrin.
 7. A system for forming and constructing a shower pan of claim 1 wherein the length-adjustable form arm is supported at its terminal end by a height-adjustable support structure with affixed stabilizing elements to form a shower pan.
 8. A method of using a system for forming and constructing a shower pan of claim 7 to form a pre-shower slope and a shower pan comprising the following steps: a) affixing a rotary mounted form tool to a drain flange wherein said rotary mounted form tool is bolted to said drain flange and said drain flange is installed in a shower area; b) affixing a radially affixed length-adjustable form arm to said rotary mounted form tool wherein said radially affixed length-adjustable form arm is located at a user selectable height such that the grade of the radially affixed length-adjustable form arm slopes towards the drain flange; c) pouring mortar into the shower area; d) rotating the radially affixed length-adjustable form arm while simultaneously adjusting its length to form a pre-shower slope wherein the grade of the radially affixed length-adjustable form arm slopes towards the drain flange; e) allowing time for the concrete pre-shower slope to cure; f) placing a plastic drain liner over the cured pre-shower slope; g) re-affixing the rotary mounted form tool to the drain riser wherein said rotary mounted form tool is screwed to said drain riser and said drain riser is installed in the shower area; h) re-affixing the radially affixed length-adjustable form arm to said rotary mounted form tool wherein said radially affixed length-adjustable form arm is located at a user selectable height above said rotary mounted form tool; i) installing a height-adjustable support structure with affixed stabilizing elements around the outer perimeter of the shower area such that the radially distant end of the length-adjustable form arm is supported on said height-adjustable support structure and the grade of the radially affixed length-adjustable form arm slopes towards the drain flange; j) pouring mortar into the shower area; and k) rotating the radially affixed length-adjustable form arm while simultaneously adjusting its length to form the mortar into a shower pan.
 9. A method scraping or forming a flat surface comprising the following steps: a) extending a length-adjustable form arm to an arbitrary length i. wherein said length-adjustable form arm is constructed of at least two interlocking segments wherein at least one of said interlocking segments may be slidable stored inside its neighboring segment; b) applying mud or plaster to a wall; and c) scraping or forming the mud or plaster to an even height using said length-adjustable form arm. 